Another "no power" problem

[sekcycles]

I have an 04 Chopper DT with no electrical power at all. I've worked on most types of bikes but never had a Big Dog.
Battery is new and reads 13.4v. With everything hooked up turning the key does nothing, no lights on EHC or anywhere else. I've checked and regreased all the connections I can locate (under tank, EHC terminals, ignition...etc) Started looking for shorts and found the horn had broken off the mount and broke the grey wire coming from the EHC, I remounted horn and reconnected the wire. Also found the white wire coming off the neutral sensor had been cut, I repaired this also. Still no power. I have found that if I disconnect the negative terminal (both main and EHC) from the battery, then turn the key to "on" then touch the EHC negative to the battery post, the EHC lights will all flash for a second. Thats about the most I've been able to get the bike to do.
It's an awesome bike and was very well taken care of and I knew it had problems when I got it (I bought it from a bank for $6500, it was a repo) but I'd sure like to hear it run someday.

 

[BadBrad]

Sure sounds like a ground fault somewhere. I hate electrical problems. And there is a possibility that your EHC has gone bad. When the lights flash on your EHC, do they all go back off? The horn wire being off shouldn't affect anything. Shitty little horns anyway. Does your horn work now? No click from the starter? Are you getting power to the key switch?

 

[sekcycles]

No power to anything, no horn, no nothing. I have power to the key switch. The lights flash on the EHC for a split second then right back off again

 

[dnespolo]

I had the same problem and my EHC was totally toasted and I went with wire plus. Hopefully is just a ground wire. Keep searching.

 

[sekcycles]

If I had the money I'd have put the WP system on by now and not worried about the headache of wondering if the EHC is bad. But as it is, searching is my only option and I have a cool looking paperweight in my garage. Also thought about selling extra parts from the bike just to pay for the WP system

 

[BadBrad]

If your EHC is fried, look into getting a Wire Plus replacement. Takes about 5 hrs for installation, but you'll never worry about reliability with the electrical system again. So, you've pulled the tank and checked all connections and wires for rubbing under the tank. Unhook your EHC and fill with dielectric grease and hook it back up. Have you pulled a plug and checked for fire? Just trying to elminate any fuel issues, but if you have no lights on your EHC with the key on and run button on, it's definitely electrical. Do you have a shop manual that shows what lights on your year model's EHC should be lit?

 

[BigDogBro1]

Maybe this will help.

Check the continuity with an ohm meter of the ignition switch to make sure it's still contacting properly when you turn on the switch.

Start with the simple stuff first and make sure battery power and good battery ground is getting to the EHC. The ignition switch when turned ON connects the Orange signal wire to GROUND to tell the EHC that the key is ON and is ready for starting.

Did you check the EHC main harness connection....disconnect the battery first before removing the harness connector.

http://i1190.photobucket.com/albums/z444/th3infamousi/2004BDWiringDiagramcopy.jpg

 

[sekcycles]

I've greased and re-greased every electrical connection on the bike and pulled apart the handlebar switch housings and headlight to look for loose or broken connections. I can't check for spark since I have no electrics. I have the wiring diagram and LED indicator sheets but since nothing lights up on the EHC I have no circuit faults to check.

 

[sekcycles]

I apologize, I forgot to mention that I have the updated EHC (gold)

 

[Sven]

Go from to the very first heavy (+) red wire to the starter motor. If that is the diagram, that reads hot. Go to the 30a fuse block. Follow that heavy red wire to the fuse side of the red. You are going to follow every wire to each connector. Grab an ohm meter and a test light. Test light from battery out to the end of the battery's source, meaning, if you have current at each end of the positive sides, then the battery ground seems to have integrity for your posi side is hot.

Follow the yellow brick road, but it's more in red code. Make sense?

 

[Th3InfamousI]

I have found that if I disconnect the negative terminal (both main and EHC) from the battery, then turn the key to "on" then touch the EHC negative to the battery post, the EHC lights will all flash for a second. Thats about the most I've been able to get the bike to do.

Sounds like either you got a bad ground wire, possibly pinched or your EHC is toasted to the max.

You said you have power to the switch which is good, and I would just confirm if you have power (12v) going to the EHC when the keyswitch is turned on. If that is all confirmed your left with the ground from the EHC or the module itself.

Have you never seen it run since you bought it?

Having no lights is no bueno :bang:

 

[sekcycles]

No, It hasn't run since I've had it. Battery was dead at the bank. But I know it had to be running recently, It still had 4 gallons of gas in the tank and the whole bike was clean clean clean!

 

[sekcycles]

I bought it just after the repo men unloaded at the bank. and the bank was going to send it to auction the next day so It was a now or never deal. I got it for what was owed on it which was next to nothing considering it's exterior condition.

 

[stlmikie]

Do you even know the mileage? Do what Th3InfamousI said and that will tell you pretty quick. Make sure the ehc is getting power. If its getting it, is it sending it. If its not sending make darn sure it is grounded properly. No groundy no worky.

 

[Brew]

I didn't see anyone mention the ignition switch. Check those connections and make sure there's no cut or shorted wires there.

 

[Th3InfamousI]

I didn't see anyone mention the ignition switch. Check those connections and make sure there's no cut or shorted wires there.

He said ignition switch was getting power, so only thing left is to make sure that the ignition switch is sending the "open" signal to the EHC. That's why I directed him to test the power wire leading to the EHC for 12v when key is turned on. :flag:

If he is not getting 12v to the EHC then the switch is NOT sending the signal back to power the EHC. So there is a bad connection between the switch and the relay to the EHC. (We didn't make it that far, I was waiting to hear his results)

If he is getting power (12v) to the EHC when key is turned on and he confirms ground is hard as a rock then its toasted. :down:

 

[Brew]

He said ignition switch was getting power, so only thing left is to make sure that the ignition switch is sending the "open" signal to the EHC. That's why I directed him to test the power wire leading to the EHC for 12v when key is turned on. :flag:

If he is not getting 12v to the EHC then the switch is NOT sending the signal back to power the EHC. So there is a bad connection between the switch and the relay to the EHC. (We didn't make it that far, I was waiting to hear his results)

If he is getting power to the EHC when key is turned on and he confirms ground is hard as a rock then its toasted. :down:

My bad didn't slow down to read it fully, yep your right I would check output from the IGN to the EHC. :2thumbs:

 

[sekcycles]

I'll be testing the ignition circuit tonight. Should have results soon I hope.

 

[sekcycles]

Done and looks like the EHC is toast...Ehc is getting power from the switch when it's on and can't find any shorts

 

[DRBarnhart]

Not to throw a kink in the works here but...

The EHC should be getting power ALL the time through a red wire going directly to the battery. It should have a ground ALL the time throught the black wire going to the battery. The only thing the ignition switch does is supply a ground signal to the EHC telling it to turn on.

You mentioned you have a newer gold EHC? Is there a circuit board plugged in to the top of the EHC that has the 50 pin connector plugged in to that?

And have you tried shorting the ignition switch wire together?

Depending on what you have there's a couple of other things to check before you pronounce the EHC DOA!!!

Dennis